International Journal of Materials Engineering Innovation (10 papers in press)
Mechanical properties of Fe+SiC metal matrix composite fabricated on stainless steel 304 by TIG coating process
by Anjani Kumar, Anil Kumar Das
Abstract: In this work, metal matrix composite (MMC) coatings were fabricated by tungsten inert gas (TIG) arcing process on stainless steel AISI 304 with iron (Fe) and silicon carbide (SiC) powder. The influence of ceramic (SiC) on the wear behavior and hardness of 10%, 20%, and 30% SiC by weight were investigated. XRD diffraction pattern revealed that the formation of metal silicide (NiSi, Fe2Si, CrSi2, and Ni3Si), iron carbide (Fe2C and Fe3C), and intermetallic compund (NiFe). EDX analysis confirmed the presence of Fe, Ni, Si, and C in coating. SEM was employed to investigate coating morphology and mode of wear mechanism. The magnified image reveals that fine-grained homogeneous structure has evolved in 20% -SiC, while agglomerated SiC particles in 30% -SiC coating due to improper dispersion of SiC in the coating during heating. Maximum microhardness was measured 663 HV0.1 in 30% -SiC and 660.5 HV0.1 in 20% -SiC; whereas average hardness was 507.7 HV0.1 and 499 HV0.1 respectively as compared to substrate hardness 220 HV0.1. Minimum wear loss was observed in 20% -SiC coating (wear height loss 301.5
Keywords: TIG coating,MMC; Microhardness; SEM-EDX; Friction and wear.
ANOVA and regression model of slurry erosion parameters of a polymeric spray paint film
by Mahmoud Heshmat, Yasser Abdelrahman
Abstract: In this paper, slurry erosion behavior of a polymeric paint film coated on steel and impacted with silica was investigated. The investigated spray paint is commonly used in automobile paint systems to provide protection against mechanical and corrosive damages. Slurry erosion tests were conducted on the designed samples to investigate the effect of the common slurry erosion parameters, namely, slurry concentration, impact angle, and impact velocity, on the mass loss of the paint material as a response. Analysis of Variance (ANOVA) was used to study the contribution of the individual parameters and investigate the significant effect of them on the mass loss of the paint material. Moreover, a regression model was developed based on the ANOVA results to predict the response (mass loss) in terms of different values of the input parameters. The developed regression model was validated with the experimental results and found to be feasible. The results revealed that the slurry erosion increases by increasing the slurry concentration and impact velocity. In addition, the rate of erosion increases with the increase of the impact angle until the angle reaches 66o. Furthermore, the ANOVA illustrated that slurry concentration and impact angle are the most significant parameters influencing the mass loss of the paint material, whilst the impact velocity had the less significant impact. The obtained statistical results were confirmed by conducting extra experimental works.
Keywords: Slurry erosion; ANOVA; regression; kendo.
Development and characterization of novel functionally graded hybrid of carbon-glass fibers
by Shamsher Singh, Sudhir Vummadisetti, Himanshu Chawla
Abstract: A functionally graded hybrid (FH) laminate has been developed using carbon and glass fibers bonded with epoxy resin. Carbon and glass fibers are dispersed layer wise in proportions throughout the laminate. The material characteristics of this laminate have been evaluated under tensile, compressive, and flexural loading conditions. Further, the properties of FH laminate are compared with sandwich and alternate hybrid laminates. In alternate hybrid laminates, carbon and glass fibers individually in alternate layers. The failure is similar as laminated composite specimens but functionally graded hybrids possess higher strength. Two types of specimens are fabricated, one with glass fiber in the core and carbon fiber on the surface and vice-versa among which specimens with glass fibers embedded in the core region performed better in terms of strength and stiffness. Analytical equations are developed based on the power law for material characterization of functionally graded hybrid composites. Stiffness and strength obtained from analytical equations show good agreement with experimental investigation. The elastic modulus, tensile and compressive strength of hybrid specimens are also determined using the rule of mixtures (ROM). It is observed that the strength and stiffness obtained from ROM is equivalent to the experimental results. It has been concluded that FH laminates have better performance in tension and compression in comparison to a sandwich hybrid, whereas sandwich hybrid laminates achieved better results in flexure. Therefore, it is noteworthy that functionally graded hybrid can replace conventional hybrids such as sandwich and alternate layers hybrid as far as uni-axial tensile or compressive strength is concerned.
Keywords: Alternate layer hybrid; functionally graded Composites; hybrid effect; sandwich hybrid.
Mechanical Properties and Surface Characterisation of Aluminium Foam Made of Al 6101 Subjected to Cryogenic Treatment A Comparative Study
by Zeenath Fathima Syed
Abstract: Aluminium alloy foams are highly utilized material because of their high ductility, low density, high thermal conductivity, and lesser cost. Cryogenics would be an unconventional methodology amongst the material fields for the improvement of mechanical properties. The cryogenic treatment of nonferrous alloy foams will also produce more wear resistance and longer durability products. This research is to investigate the mechanical properties and microstructural characteristics of closed cell aluminium foam made of Al 6101 aluminium alloy with different heat regimes namely Heat Treatment (HT), Cryogenic Treatment (CT), and Cryogenic Heat Treatment (CHT). The experimental results reveal that the cryogenic treatment of Al 6101 foam decreases the elastic limit and leads to brittleness. Comparison of stress-strain curve emphasizes that the increase of brittleness in the CHT regime is due to the reduction of the elastic region and also the scanning electron microscopic images prove that the cryogenic treatment changes the morphology of aluminium alloy foam.
Keywords: Cryogenics; Aluminium foam; Heat Treatment; Cryogenic Treatment; Cryogenic Heat Treatment; Characterisation; Mechanical properties.
Parametric study of Sisal-Epoxy resin composite treated in sodium bicarbonate solution using Taguchi Orthogonal array
by Sahil Kansal, Ajay Singh Verma, Suman Kant, Pankaj
Abstract: The sisal-fibre reinforced epoxy composite is fabricated with hand layup method using Taguchi L9 orthogonal array. The novelty of the present investigation is treatment of fibres with sodium bicarbonate, which is economical and eco-friendly as compared to other alkaline treatments like sodium hydroxide, isocyanate triazine in development of epoxy composite. The controlled process parameters viz. fibre length (mm), fibre content (wt%), and concentration of sodium bicarbonate (wt% by vol.) is considered in maximizing the output response characteristic i.e. tensile strength (Mpa). The average output response characteristic is measured as per ASTM D638 at defined set of experimentation condition. Moreover, variation in output response characteristics is predicted through ANOVA and significant effect of individual process parameters are identified. The statistical analysis exhibits that the fibre length is the most significant parameter in maximizing the output response followed by sodium bicarbonate concentration, and fibre content. It is also observed that the maximum average tensile strength is achieved 79.93 Mpa with 6 mm fibre length, 20 wt% fibre content, and 10 wt% by vol. sodium bicarbonate in development of sisal-fibre reinforced epoxy composite.
Keywords: epoxy resin; Sisal fibre; sodium bicarbonate (NaHCO3); Taguchi; ANOVA.
Investigation and Wear Analysis of Al-SiCp Nano Composites and Study of its Machinability using Electro Discharge Machining
by Pradyut Kumar Swain, Kasinath Das Mohapatra, Pratyush Kumar Swain, Ratnakar Das
Abstract: The present research work has been given the importance on proper distribution of silicon carbide nano particles with different volume fractions of 1%, 1.5% and 2% in the aluminium metal matrix. The paper also deals with the wear analysis of the developed Al-SiCp nano composite by using dry sliding wear test with pin on disc machine. XRD analysis of the Al-SiCp nano composite work material has been performed to determine the purity and grain size of the sample. The present work also focuses on metal matrix nano composites during Electric discharge machining (EDM) process using brass, aluminium and copper as tool electrodes. Electrode wear ratio (EWR) of the tool as well as material removal rate (MRR) of the workpiece has been determined and it was found that copper is the best and preferable electrode followed by aluminium and brass electrodes due to its higher MRR and lower EWR.
Keywords: Wear; Material removal rate; Electrode wear ratio; Electro Discharge Machining; XRD; Nano Composite; Purity; Grain size.
Influence of substrate bias on performance of diamond coating on WC cutting inserts for machining of aluminium by HFCVD process
by DILIP KUMAR SAHU, SAROJ KUMAR SARANGI, Kakarla Udaya Sri
Abstract: The most important factors during deposition on different carbide base cutting tool inserts by using Hot Filament Chemical Vapour Deposition (HFCVD) method are nucleation and growth of diamond. The negative dc biasing is the most outstanding technique in HFCVD method for improving the nucleation on the substrate surface. In the present investigation, the main objective is to analyse the influence of bias voltage on the WC substrate for nucleation, growth, adhesion and quality of diamond coating along with evaluation of machining performance in dry environment. Finally it has been confirmed that higher nucleation density including good quality diamond coatings along with reduced cutting force and better work surface finish were achieved under a definite reaction pressure with negative substrate bias.
Keywords: nucleation; coating; substrate bias; adhesion.
Magnetoelectricity of Barium Titanate/Cobalt Ferrite Nanoparticles Incorporated into Poly(vinylidene fluoride-co-trifluoroethylene) Copolymer Films
Abstract: Incorporating ferroelectric and ferromagnetic nanoparticles into copolymers can produce composites with novel properties for broad applications especially in electronics. In this research, nanoparticles of barium titanate (BTO) and cobalt iron oxide (CFO) were chemically synthesized and then individually incorporated in Poly(vinylidene fluoride-co-trifluoroethylene) to form multi-layered magnetoelectric film. BTO-P(VDF-TrFE)/CFO-P(VDF-TrFE)/BTO-P(VDF-TrFE) sandwich type films -(20-30
Keywords: Multiferroics; Barium Titanate; Cobalt Ferrite; Magnetoelectric; Nanoparticles; Film.
Investigating the significance of SiC particle size on the mechanical properties of Cu-6Sn-SiC composite
by Karthik. V. Shankar, Mr Ajay Gosh, Sudhin C B, Arvind S. Pai, Akshay Biju, K.R. Sriram
Abstract: The existing research is to manufacture bronze metal matrix composite with varying average SiC particle size (30
Keywords: SiC particle size; Bronze metal matrix; mechanical properties; fracture; Cu-Sn.
Monitoring of Hole Quality in Friction Drilling using different Machine Learning Techniques
by Narayana Moorthy N, Kanish T.C
Abstract: The present investigation deals with monitoring the bush and collar formation during the friction drilling process of Be-Cu alloy. Being the aerospace-grade material having a combination of better mechanical properties and corrosion resistance, this alloy has been chosen for the study. As the alloys are usually subjected to extreme heat during the friction drilling process, they are often prone to damage in terms of alteration in the structure as well as irregular bush formation. Hence, monitoring the quality of the hole during the process becomes inevitable when it comes to the hard and tough materials like Be-Cu alloy. In the current study, the quality of the drilled hole was monitored using different machine learning (ML) techniques vis-
Keywords: Friction drilling; Bush formation; Wavelet Transform; Feature extraction; Classifiers.